Coatings for a razor blade

ABSTRACT

A razor blade including: a substrate having a tip portion including a tip region, a blade body including a base, and first and second outer sides disposed opposite a split line of the substrate, in which the first and second outer sides converge at a tip, the first outer side comprises a first coating disposed substantially thereon and extending from the tip region toward the base, and a first portion of the second outer side is substantially free of any coating, the first portion extending from the tip region toward the base or being spaced apart from the tip region and the base. Also provided is a method of coating the razor blade.

FIELD OF THE INVENTION

The invention generally relates to coating of substrates, and moreparticularly to improved coatings on razor components, such as razorblades.

BACKGROUND OF THE INVENTION

A razor blade is typically formed of a suitable substrate material, suchas stainless steel, with a cutting edge formed with a wedge-shapedconfiguration with an ultimate tip having a radius less than about 1000angstroms (Å), e.g., about 200-300 Å. One or more hard coatings, such asdiamond, amorphous diamond, diamond-like carbon (DLC) material,nitrides, carbides, oxides, or ceramics, may be applied to the substratematerial, particularly the cutting edge, to improve strength, corrosionresistance, and shaving ability and to maintain needed strength whilepermitting thinner edges with lower cutting forces to be used. One ormore soft coatings generally of polymeric material, such aspolytetrafluoroethylene (PTFE), may be layered on top of the hardcoating(s) to impart lubricity and reduce friction. Interlayers ofniobium or chromium-containing materials can aid in improving thebinding between the substrate, typically stainless steel, and hardcarbon coatings, such as DLC. The coatings may be applied using anysuitable method, such as Physical Vapor Deposition (PVD) techniques forthe hard coating(s) and dipping, spraying, and/or brushing for the softcoating(s). Examples of razor blades and processes of manufacture aredescribed in U.S. Pat. Nos. 5,295,305; 5,232,568; 4,933,058; 5,032,243;5,497,550; 5,940,975; and 5,669,144; EP 0591339; and PCT 92/03330, whichare hereby incorporated by reference.

Conventional blades typically include a generally equal amount ofmaterial(s) on both sides of the substrate, often applied by vapordeposition parallel to the cutting edge. The coatings on these bladesare highly symmetrical and include a substantially similar composition,coverage area, microstructure, etc. on both sides of the cutting edge.While current razor blades perform adequately, in order for nextgeneration products to perform better, improvements to interactionsbetween the blade and skin and the blade and hair can be made.

SUMMARY OF THE INVENTION

In accordance with an aspect of the present disclosure, a razor blade isprovided, which includes: a substrate having a tip portion comprising atip region, a blade body including a base, and first and second outersides disposed opposite a split line of the substrate, wherein the firstand second outer sides converge at a tip. The first outer side includesa first coating disposed substantially thereon, the first coatingextending from the tip region toward the base, and a first portion ofthe second outer side is substantially free of any coating, in which thefirst portion extends from the tip region toward the base or is spacedapart from the tip region and the base.

In accordance with another aspect of the present disclosure, a method ofcoating a razor blade is provided, in which the razor blade includes asubstrate having a tip portion including a tip region, a blade bodyincluding a base, and first and second outer sides disposed opposite asplit line of the substrate, wherein the first and second outer sidesconverge at a tip, the method including one of: (i) applying a firstcoating only to a portion of the first outer side, the coating extendingfrom the tip region toward the base and being disposed substantially onthe first outer side; or (ii) applying a first coating to a portion ofthe first outer side, the first coating extending from the tip regiontoward the base and being disposed substantially on the first outerside, and applying a second coating to the second outer side such that afirst portion of the second outer side is substantially free of anycoating and a second portion of the second outer side comprises thesecond coating, wherein the first portion extends from the tip regiontoward the base or is spaced apart from the tip region and the base.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which like designations are used todesignate substantially identical elements, and in which:

FIG. 1 is a front view of a razor system comprising a handle and a razorcartridge in accordance with the present disclosure;

FIG. 2 is a side view of a razor blade with a symmetrical substrate inaccordance with the present disclosure;

FIG. 3 is a perspective view of a tip portion of another razor bladewith a symmetrical substrate in accordance with the present disclosure;

FIGS. 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, and 17 are sideviews of the tip portion of the razor blade of FIG. 3 comprising one ormore coatings in accordance with the present disclosure;

FIG. 18 is a side view of a razor blade with an asymmetrical substratein accordance with the present disclosure;

FIG. 19 is a side view of another razor blade with an asymmetricalsubstrate in accordance with the present disclosure;

FIGS. 20A, 20B, 21A, 21B, 22A, 22B, 23A, 23B, 24A, 24B, 25A, 25B, 26A,26B, 27A, 27B, 28A, 28B, 29A, 29B, 30A, 30B, 31, 32 and 33 are sideviews of a tip portion of the razor blade of FIG. 18 comprising one ormore coatings in accordance with the present disclosure;

FIG. 34 is a detailed side view of a tip region of the razor blade ofFIGS. 4 and 20;

FIGS. 35, 36, and 37 are additional detailed side views similar to FIG.34 of tip regions of razor blades comprising one or more coatings inaccordance with the present disclosure;

FIG. 38 is a schematic of a chamber showing razor blades capable ofbeing coated via a deposition technique in accordance with the presentdisclosure; and

FIG. 39 is a flow diagram illustrating an exemplary method of coating arazor blade in accordance with the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The term “asymmetric blade,” as used herein, means a blade defined by asubstrate having a first portion comprising a blade body and a secondportion comprising a tip portion wherein a split line passes through atip of the tip portion, extends through the first and second portionsand separates the second portion into generally asymmetric first andsecond sections. The outer surface of the first section of the secondportion is asymmetric with regards to the outer surface of the secondsection. The outer surface of the first section of the second portionmay function as a skin-contacting surface, and the outer surface of thesecond section may function as a hair-cutting surface.

A “split line,” as used herein, means a line extending through the tipof the tip portion of the blade substrate, separates the second portioninto asymmetrical first and second sections and is generally parallelwith first and second generally parallel outer surfaces of the firstportion defining the blade body of the blade substrate.

With reference to FIG. 1, a shaving razor system 10 comprises a handle12 and a razor cartridge 14. In some examples, the razor cartridge 14may be detachably mounted to the handle 12 with a connector 20, asshown, and in other examples, the razor cartridge 14 may be attachedpermanently to the handle 12. The razor cartridge 14 may pivot relativeto the handle 12. The razor cartridge 14 may include a cartridge housing16 having one or more razor blades 18. Although three blades are shownin FIG. 1, it is understood that any number of blades, more or less, maybe mounted within the razor cartridge 14. The razor blades 18 may bemounted within the cartridge housing 16 and secured with clips 24 a and24 b as shown. The cartridge housing 16 may further comprise a cap 22located near a back of the cartridge housing 16 and one or more guardstructures 26 located near a front of the cartridge housing 16. The cap22 may comprise one or more lubrication members (not labeled).

FIG. 2 is a side view of a razor blade 8 in accordance with the presentdisclosure, and FIGS. 3 and 4 are detailed perspective and side views,respectively, of elements of a razor blade 18 in accordance with thepresent disclosure. The razor blades 8 and 18 shown in FIGS. 2-4 mayeach comprise a substrate 28 comprising a first portion with a bladebody 30 and a second portion with a tip portion 34. As used herein, a“substrate” signifies the substance or material acted upon by thedeposition process(es) in the present disclosure. Illustrativeembodiments herein relate to a stainless steel substrate commonly usedfor razor blade formation. It is contemplated that the substrate of thepresent invention may also be comprised of other metals, plastic,ceramic, or any other material. The blade body 30 may comprise a base32, and the tip portion 34 may comprise flanks 36 that converge at a tip40 to define a cutting edge 42 of the substrate 28, which performs thecutting of hair. The flanks 36 may each comprise one or more bevels orfacets 38, as described herein.

In the example illustrated in FIGS. 2-4, the substrate 28 issubstantially symmetrical and may comprise a split line SL₂₈ that passesthrough the tip 40 and divides or separates the substrate 28 intosubstantially equal first and second sections or halves 44 and 46. Oneouter side 48 (also referred to herein as a first outer side) of thesubstrate 28 is disposed opposite the split line SL₂₈ with respect tothe other outer side 50 (also referred to herein as the second outerside). As used herein, the terms “first” and “second” are for referenceonly and are not intended to be limiting.

At least a portion of one outer side of the substrate 28, e.g., thefirst outer side 48, may define a skin-contacting surface, and at leasta portion of the other outer side, e.g., the second outer side 50, maydefine a hair-cutting surface. It was determined that the two sides ofthe razor blade generally perform different functions (e.g., a bottomside that contacts the skin and a top side that performs cutting of thehair, in which both sides perform cutting of the hair with the top side(e.g., away from the skin) having a larger influence). Studies haveshown that placing Teflon on one bevel and no Teflon on the otherdisplay completely different cutting forces depending on whether theTeflon coated bevel is placed skin side up (e.g., away from the skin)versus skin side down (e.g., closer to the skin). When razor blades withno Teflon coating on one side are placed such that that side (e.g., noTeflon coating) is skin side down, only small cutting force increaseswere noted when compared to blades having Teflon on both sides, but whenrazor blades with no Teflon coating are placed skin side up verysignificant cutting force increases were measured when compared toblades having Teflon on both sides.

With reference to FIG. 4, the tip portion 34 may comprise a first flank36A defined by a portion of the first outer side 48 and a second flank36B defined by a portion of the second outer side 50, in which the firstand second flanks 36A and 36B converge at the tip 40. The first flank36A may comprise one or more first facets, e.g., first and third facets38A and 38C, and the second flank 36B may comprise one or more secondfacets, e.g., second and fourth facets 38B and 38D. The first facet 38Ameets the blade body 30 at a first junction 39-1 and extends between theblade body 30 and the third facet 38C on the first outer side 48 of thesubstrate 28. The third facet 38C meets the first facet 38A at a secondjunction 39-2 and extends between the first facet 38A and the tip 40 onthe first outer side 48. On the second outer side 50 of the substrate28, the second facet 38B meets the blade body 30 at a third junction39-3 and extends between the blade body 30 and the fourth facet 38D. Thefourth facet 38D meets the second facet 38B at a fourth junction 39-4and extends between the second facet 38B and the tip 40 on the secondouter side 50. The third and fourth facets 38C and 38D, which may alsobe referred to as end facets, converge at the tip 40 to define thecutting edge 42. In other examples, the flanks 36 may each include onefacet 38 (see the razor blade 8 in FIG. 2) or three or more facets (notshown). In the razor blades 8 and 18 shown in FIGS. 2-4, an outer shapeor geometry of the first outer side 48 may be substantially the same asan outer shape or geometry of the second outer side 50. For example, thefirst facet 38A may substantially correspond to the second facet 38B andmay comprise a substantially similar length, as defined between thefirst and second junctions 39-1 and 39-2 and between the third andfourth junctions 39-3 and 39-4, respectively. The third facet 38C maysimilarly substantially correspond to the fourth facet 38D and maycomprise a substantially similar length, as defined between the tip 40and the second junction 39-2 and the tip 40 and the fourth junction39-4, respectively. It follows that the angles at the junctions 39-1 and39-3, and the angles at the junctions 39-2 and 39-4 may also generallybe substantially similar.

With continued reference to FIG. 4, the razor blade 18 may comprise aplurality of outer surfaces, including first and second blade body outersurfaces 31A and 31B defined by outer surfaces of the first and secondportions 30A and 30B, respectively, of the blade body 30; and first,second, third, and fourth facet outer surfaces 39A, 39B, 39C, and 39Ddefined by outer surfaces of the first, second, third, and fourth facets38A, 38B, 38C, and 38D, respectively. The first outer side 48 of thesubstrate 28 includes the first blade body outer surface 31A and thefirst and third facet outer surfaces 39A and 39C. The second outer side50 includes the second blade body outer surface 31B and the second andfourth facet outer surfaces 39B and 39D. The first and second blade bodyouter surfaces 31A and 31B may be generally parallel to each other, andthe split line SL₂₈ may be generally parallel with the first and secondblade body outer surfaces 31A and 31B. The first and second outer sides48 and 50 converge at the tip 40 to define the cutting edge 42 of thesubstrate 28.

FIGS. 18 and 19 are side views illustrating exemplary embodiments ofrazor blades 118 and 118′ in accordance with the present disclosure.Each razor blade 118, 118′ may comprise a substrate 128, 128′ comprisinga first portion comprising a blade body 130, 130′ and a second portioncomprising a tip portion 134, 134′. The blade body 130, 130′ maycomprise a base 132 (not shown in FIG. 19), and the tip portion 134,134′ may comprise flanks 136A, 136B and 136A′, 136B′ that converge at arespective tip 140, 140′ to define a cutting edge (not labeled) of therespective substrate 128, 128′. The flanks 136, 136′ may each compriseone or more respective bevels or facets, as described herein. Thesubstrates 128, 128′ may be asymmetrical, with a split line SL₁₂₈,SL_(128′) that passes through the tip 140, 140′, is parallel to theblade body outer surfaces 131A and 131B, and divides or separates thesubstrate 128, 128′ into asymmetrical first and second sections orhalves 144, 144′ and 146, 146′. With reference to FIG. 18, a first outerside 148 of the substrate 128 is disposed opposite the split line SL₁₂₈with respect to a second outer side 150. With reference to FIG. 19, afirst outer side 148′ of the substrate 128′ is disposed opposite thesplit line SL_(128′) with respect to a second outer side 150′. At leasta portion of one outer side of each respective substrate 128, 128′,e.g., the first outer side 148, 148′, may define a skin-contactingsurface, and at least a portion of the other outer side, e.g., thesecond outer side 150, 150′, may define a hair-cutting surface.

In the example shown in FIG. 18, the tip portion 134 of the substrate128 may comprise a first flank 136A defined by a portion of the firstouter side 148 and a second flank 136B defined by a portion of thesecond outer side 150. The first flank 136A may comprise one or morefirst facets, e.g., first and third facets 138A and 138C, and the secondflank 136B may comprise one or more second facets, e.g., second andfourth facets 138B and 138D. On the first outer side 148 of thesubstrate 128, the first facet 138A meets the blade body 130 at a firstjunction 139-1 and extends between the blade body 130 and the thirdfacet 138C; and the third facet 138C meets the first facet 138A at asecond junction 139-2 and extends between the first facet 138A and thetip 140. On the second outer side 150 of the substrate 128, the secondfacet 138B meets the blade body 130 at a third junction 139-3 andextends between the blade body 130 and the fourth facet 138D; and thefourth facet 138D meets the second facet 138B at a fourth junction 139-4and extends between the second facet 138B and the tip 140. The third andfourth facets 138C and 138D, which may also be referred to as endfacets, converge at the tip 140 to define the cutting edge of thesubstrate 128.

In the example shown in FIG. 19, the tip portion 134′ of the substrate128′ may comprise a first flank 136A′ defined by a portion of the firstouter side 148′ and a second flank 136B′ defined by a portion of thesecond outer side 150′. The first flank 136A′ may comprise one or morefirst facets, e.g., first and third facets 138A′ and 138C′, and thesecond flank 136B′ may comprise one or more second facets, e.g., asecond facet 138B′. On the first outer side 148′ of the substrate 128′,the first facet 138A′ meets the blade body 130′ at a first junction139-1′ and extends between the blade body 130′ and the third facet138C′; and the third facet 138C′ meets the first facet 138A′ at a secondjunction 139-2′ and extends between the first facet 138A′ and the tip140′. On the second outer side 150′ of the substrate 128′, the secondfacet 138B′ meets the blade body 130 at a third junction 139-3′ andextends between the blade body 130′ and the tip 140′. The second andthird facets 138B′ and 138C′, which may also be referred to as endfacets, converge at the tip 140′ to define the cutting edge of thesubstrate 128′.

Because the substrates 128, 128′ are asymmetrical, an outer shape orgeometry of the first outer side 148, 148′ is different from an outershape or geometry of the second outer side 150, 150′. For example, withreference to FIG. 18, the first facet 138A may comprise a differentlength, as compared to the second facet 138B, with the lengths beingdefined between the first and second junctions 139-1 and 139-2 and thethird and fourth junctions 139-3 and 139-4, respectively. In someexamples, the length of the first facet 138A may be greater than thelength of the second facet 138B, and in other examples, the length ofthe first facet 138A may be less than the length of the second facet138B. The third facet 138C may similarly comprise a different length, ascompared to the fourth facet 138D, with the lengths being definedbetween the tip 140 and the second junction 139-2 and the fourthjunction 139-4, respectively. In some examples, the length of the thirdfacet 138C may be greater than the length of the fourth facet 138D, andin other examples, the length of the third facet 138C may be less thanthe length of the fourth facet 138D.

With reference to FIG. 19, the first outer side 148′ comprises twofacets 138A′ and 138C′, and the second outer side 150′ comprises onlyone facet 138B′. The third facet 138C′ may similarly comprise adifferent length, as compared to the second facet 138B′, with thelengths being defined between the tip 140′ and the second junction139-2′ and the third junction 139-3′, respectively. In some examples,the length of the third facet 138C′ may be greater than the length ofthe second facet 138B′, and in other examples, the length of the thirdfacet 138C′ may be less than the length of the second facet 138B′.

Each of the razor blades 118, 118′ may comprise a plurality of outersurfaces. With reference to FIG. 18, the razor blade 118 comprises firstand second blade body outer surfaces 131A and 131B defined by outersurfaces of first and second portions 130A and 130B, respectively, ofthe blade body 130; and first, second, third, and fourth facet outersurfaces 139A, 139B, 139C, and 139D defined by outer surfaces of thefirst, second, third, and fourth facets 138A, 138B, 138C, and 138D,respectively. The first and second blade body outer surfaces 131A and131B may be generally parallel to each other, and the split line SL₁₂₈may be generally parallel with the first and second blade body outersurfaces 131A and 131B. The first outer side 148 of the substrate 12815702 9 includes the first blade body outer surface 131A and the firstand third facet outer surfaces 139A and 139C, and the second outer side150 includes the second blade body outer surface 131B and the second andfourth facet outer surfaces 139B and 139D. The first and second outersides 148 and 150 converge at the tip 140 to define the cutting edge ofthe substrate 128. The second and fourth facets 138B and 138D may belocated closer to the split line SL₁₂₈ than the first and third facets138A and 138C, such that the first half 144 of the substrate 128 islarger than the second half 146.

With reference to FIG. 19, the razor blade 118′ comprises first andsecond blade body outer surfaces 131A′ and 131B′ defined by outersurfaces of the first and second portions 130A′ and 130B′, respectively,of the blade body 130′; and first, second, and third facet outersurfaces 139A′, 139B′, and 139C′ defined by outer surfaces of the first,second, and third facets 138A′, 138B′, and 138C′, respectively. Thefirst and second blade body outer surfaces 131A′ and 131B′ may begenerally parallel to each other, and the split line SL_(128′) may begenerally parallel with the first and second blade body outer surfaces131A′ and 131B′. The first outer side 148′ of the substrate 128′includes the first blade body outer surface 131A′ and the first andthird facet outer surfaces 139A′ and 139C′, and the second outer side150′ includes the second blade body outer surface 131B′ and the secondfacet outer surface 139B′. The first and second outer sides 148′ and150′ converge at the tip 140′ to define the cutting edge of thesubstrate 128′. The second facet 138B′ may be located closer to thesplit line SL_(128′) than the first and third facets 138A′ and 138C′,such that the first half 144′ of the substrate 128′ is larger than thesecond half 146′.

Razor blades in accordance with the present disclosure may comprise acoating disposed substantially on one or both outer sides of the razorblade, in which at least a portion of one outer side is free of anycoating. A “layer” as used herein may signify at least one material on arazor blade satisfied by a variety of factors, including but not limitedto, the composition, morphology, or structure of the layer(s); thepresence of a boundary between layers; whether the process used to makethe product is expected to result in one or more layers; and whetherthere is a sufficient change in composition or morphology as to resultin one or more layers. As one example, there may be only one type ofmaterial on the razor blade but with distinguishable layers, each layerhaving a different morphology. As used herein, a “coating” may signifyone or more layers on a razor blade, in which each layer comprises oneor more materials. Thus, the present invention “coating” may be definedby a single layer or by multiple layers. The present invention alsocontemplates the term “coating” to signify the overall or total coatingon one side of the razor blade, which includes all of the layers on thatone side of the razor blade.

In particular, a “coating” as used herein includes all layer(s) ofmaterial(s) applied to one outer side of the razor blade. For example, acoating may include one or more layers as defined herein, such as afirst layer that is disposed substantially on a portion or the entiretyof one outer side of the razor blade; a second layer that is formed ontop of at least a portion of the first layer; a third layer that isformed on top of at least a portion of the second layer; and so on. Acoating may further include a plurality of sections that are disposedsubstantially on one outer side of the razor blade, wherein each sectionmay comprise one or more layers of material(s). For example, the coatingmay comprise a first section that extends substantially from a firstpoint or location on one outer side of a razor blade to a second pointor location on the one outer side; a second section that extendssubstantially from the second point or location to a third point orlocation on the one outer side; a third section that extendssubstantially from the third point or location to a fourth point orlocation on the one outer side; and so on, in which each section issubstantially different from an adjacent section, as described in detailherein.

As used herein to, the phrases “disposed substantially on,” “extendingsubstantially from,” and similar phrases are used to describe a locationor position of each coating, including one or more layers and/orsections thereof, and signifies that a majority of thecoating/layer/section is disposed on an indicated outer side and/orsurface(s) of the razor blade and/or that a majority of thecoating/layer/section extends between two indicated points or locationson the outer side and/or surface(s) of the razor blade. As describedherein with respect to FIGS. 34-37, these phrases may encompassstructures in which a portion of the coating/layer/section extends overthe tip and onto the other outer side or surface; overlaps onto anadjacent outer side or surface; extends slightly beyond the twoindicated points or locations on the surface; or extends slightly past,or stops slightly short of, an identified junction between adjacentfacets or between the blade body and a facet.

In accordance with the present disclosure, one outer side of a razorblade comprises a coating, and at least a portion of the other outerside of the razor blade is free of any coating. FIGS. 4-17 illustrateexemplary coatings with respect to an asymmetrical razor blade 18 havinga symmetrical substrate 28, and FIGS. 20-33 illustrate exemplarycoatings with respect to an asymmetrical razor blade 118 having anasymmetrical substrate 128. Some labeling in FIGS. 5-17 and 20-33 isremoved to illustrate other aspects of the structure in detail.

As used herein, the terms “symmetrical,” “asymmetrical,” and derivativesthereof may refer to an outer shape of a substrate that defines a razorblade and/or to coating(s) formed thereon, as determined with respect toa split line of the substrate. For example, the substrate 28 in FIG. 4is substantially symmetrical (i.e., the split line SL₂₈ divides thesubstrate 28 into substantially equal sections/halves 44 and 46 withsubstantially similar outer shapes that are generally mirror images ofeach other), but the coating(s) formed on the substrate 28 in accordancewith the present disclosure may be asymmetrical, as described herein indetail, such that the razor blade 18 is asymmetrical. The substrate 128in FIG. 18 and the coatings formed thereon are both asymmetrical, asdescribed herein, such that the razor blade 118 is asymmetrical.

In FIGS. 4-17, one outer side, e.g., the first outer side 48, of thesubstrate 28 may comprise a coating, and at least a portion 51 of theother outer side, e.g., the second outer side 50, of the substrate 28may be substantially free of any coating. In some examples, at least aportion of the first outer side 48 may define a skin-contacting surface.The portion 51 may extend from the tip region 35 toward the base 32, asshown in FIGS. 4-16, or may be spaced apart from the tip region 35 andthe base 32, as shown in FIG. 17. It is reemphasized that the terms“first” and “second” as used herein are for reference only and are notintended to be limiting. For example, although the lefthand side of thesubstrate 28 in FIGS. 4-17 is referred to as the “first” outer side, itis understood that the righthand side of the substrate 28 could also bethe “first” outer side.

With reference to FIGS. 4-6, the razor blade 18 may comprise a coating60 disposed substantially on the first outer side 48 of the substrate28. In some examples, the coating 60 may comprise a single layer ofmaterial, as shown in FIG. 4. In other examples, the coating 60 maycomprise a plurality of layers of material(s), as shown in FIGS. 5 and 6and described in detail herein. The coating 60 extends from a tip region35 toward the base 32 (see FIG. 4) along the first outer side 48 of thesubstrate 28. As shown in FIG. 4, the tip portion 34 of the substrate 28comprises the tip region 35, in which the tip region 35 encompasses,i.e., includes, the tip 40 plus a portion of the substrate 28 extendingfrom the tip 40 toward the base 32 by about 1 μM along the first andsecond outer sides 48 and 50, as shown in FIG. 34.

With reference to FIG. 5, in some examples, the coating 60 may comprisefirst and second layers 60A and 60B, in which the first layer 60A isdisposed substantially on the first outer side 48 and the second layer60B is formed on top of at least a portion of the first layer 60A. Withreference to FIG. 6, in other examples, the first coating 60 maycomprise at first, second, and third layers 60A-60C, in which the firstlayer 60A is disposed substantially on the first outer side 48, thesecond layer 60B is formed on top of at least a portion of the firstlayer 60A, and the third layer 60C is formed on top of at least aportion of the second layer 60B. As described herein, the coating 60and/or any of the layers 60A-60C thereof may be subjected to ionimplantation to generate, for example, a layer 60′ comprising anion-implanted material 61 shown in FIG. 13.

In the examples shown in FIGS. 4-6, the coating 60 (including all layers60A-60C thereof) is depicted as extending along the first outer side 48of the substrate 28 from the tip region 35 onto the blade body 30, andin some instances, all the way to the base 32 of the razor blade 18 asshown in FIG. 4. In other examples, as shown in FIGS. 7 and 8, thecoating and/or one or more layers thereof may stop short of the bladebody 30 and/or the base 32, and in some particular examples, the coatingand/or one or more layers thereof may be disposed substantially only onthe tip portion 34 of the substrate 28, e.g., on one or both of thefirst and third facets 38A and 38C.

With reference to FIGS. 7 and 8 and the labeling of the substrate 28 inFIG. 4, a coating 64, 68 may comprise one or more layers including arespective first layer 64A, 68A and second layer 64B, 68B. The firstlayer 64A, 68A is disposed substantially on, and extends along a portionof, the first outer side 48 of the substrate 28 from the tip region 35toward the base 32 for a respective first distance D₁, D_(1′). Thesecond layer 64B, 68B is formed on top of at least a portion of therespective first layer 64A, 68B and extends from the tip region 35toward the base 32 for a respective second distance D₂, D_(2′). In someexamples, the second distance D₂, D_(2′) may be less than the respectivefirst distance D₁, D_(1′). In FIG. 7, the first layer 64A may extendalong the first outer side 48 from the tip region 35 onto the blade body30 and toward the base 32, and the second layer 64B may be disposedsubstantially on the first and third facets 38A and 38C, with the secondlayer 64B extending from the tip region 35 to about the first junction39-1 between the first facet 38A and the blade body 30. In FIG. 8, thefirst layer 68A may extend along the first outer side 48 from the tipregion 35 onto the blade body 30 and toward the base 32, and the secondlayer 68B may be disposed substantially on the third facet 38C, with thesecond layer 68B extending from the tip region 35 to about the secondjunction 39-2 between the first and second facets 38A and 38B. In otherexamples, the second distance D₂, D_(2′) may be about the same as therespective first distance D₁, D_(1′). In some instances, the first andsecond layers may both be disposed on the first and third facets 38A and38C or only on the third facet 38C. With continued reference to FIGS. 7and 8, in some configurations, the coatings 64 and 68 may comprise twoor more layers, e.g., the first layer 64A, 68A and the second layer 64B,68B. In other configurations, the coatings 64 and 68 may comprise onlythe second layer 64B and 68B (the first 64A and 68A are shown in dashedlines in FIGS. 7 and 8 indicating that they are optional).

With reference to FIGS. 9-11, in further examples, a coating 72substantially disposed on the first outer side 48 may comprise two ormore sections. As shown in FIGS. 9 and 10, the coating 72 may comprise afirst section 72-1 and a second section 72-2. The first section 72-1 ofthe coating 72 may extend along the first outer side 48 substantiallyfrom a first point or location 73-1, which may substantially correspondto a tip region 35 of the substrate 28, to a second point or location73-2 on the first outer side 48. The second section 72-2 may extendsubstantially from the second location 73-2 to a third point or location73-3 on the first outer side 48. With reference to FIG. 9 and thelabeling of the substrate 28 in FIG. 4, the second location 73-2 may bepositioned at about a junction between a facet and the blade body 30,e.g., junction 39-1 between the first facet 38A and the blade body 30,such that the first section 72-1 may be located substantially on thefirst and third facets 38A and 38C on the first outer side 48 and thesecond section 72-2 may be located substantially on the blade body 30.With reference to FIG. 10 and the labeling of the substrate 28 in FIG.4, the second location 73-2 may be positioned at about a junctionbetween two adjacent facets, e.g., junction 39-2 between the first andthird facets 38A and 38C, such that the first section 72-1 is locatedsubstantially on the third facet 38C. In the examples depicted in FIGS.9 and 10, the third location 73-3 may be spaced apart from the secondlocation 73-2 and may be located, for example, toward or near the base32 of the substrate 28, as shown in FIG. 9.

As shown in FIG. 11, the coating 72 may comprise first, second, andthird sections 72-1, 72-2, and 72-3. The first section 72-1 may extendalong the first outer side 48 substantially from a first point orlocation 73-1, which may substantially correspond to a tip region 35 ofthe substrate 28, to a second point or location 73-2 on the first outerside 48; the second section 72-2 may extend substantially from thesecond location 73-2 to a third point or location 73-3 on the firstouter side 48; and the third section 72-3 may extend substantially fromthe third location 73-3 to a fourth point or location (not shown) on thefirst outer side 48. With reference to FIG. 11 and the labeling of thesubstrate 28 in FIG. 4, the second location 73-2 may be positioned atabout the junction 39-2 between the first and third facets 38A and 38C,and the third location 73-3 may be positioned at about the junction 39-1between the first facet 38A and the blade body, such that the first andsecond sections 72-1 and 72-2 may be disposed substantially on the firstand third facets 38A and 38C, respectively, and the third section 72-3may be located substantially on the blade body 30. The fourth locationmay be spaced apart from the third location 73-3 and may be located, forexample, toward or near the base 32 of the substrate 28.

With reference to FIG. 12, in further examples, the substrate 28 maycomprise a coating 76 with a thickness that varies along at least asection of the coating 76 in a direction extending from the tip region35 toward the base 32, in which the thickness is measured between anouter surface 76A of the coating 76 and an outer surface 28A of thesubstrate 28. The coating 76 may, for example, increase in thickness, asshown in FIG. 12.

In the examples shown in FIGS. 4-12, an outer shape of the coatings 60,64, 68, 72, and 76 (and all layers or sections thereof) generallyconform to and/or mirror an outer shape of the underlying portions ofthe substrate 28 on which the coatings are formed. In other examples, asshown in FIG. 14, the substrate 28 may comprise a coating 80 with one ormore sections that define an outer shape that is different from an outershape of an underlying portion of the substrate 28. The coating 80 maycomprise a thickened section 80A where the coating 80 bulges outwardfrom the substrate 28 and forms an outer shape that is different from anouter shape of one or more of the underlying portions of the substrate28, e.g., the first and third facet outer surfaces (not labeled; seefacet outer surfaces 39A and 39C in FIG. 4). The coating 80 mayoptionally comprise a second section 80B with an outer shape thatconforms more closely to the outer shape of the underlying portion(s),e.g., the first blade body outer surface (not labeled; see blade bodyouter surface 31A in FIG. 4), of the substrate 28.

In FIGS. 4-17, the coating 60, 64, 68, 72, 76, and 80 may be disposed onone or both of the first facets (i.e., the first and/or third facets 38Aand 38C) on the first outer side 48, and the portion 51 of the secondouter side 50 that is free of any coating may comprise at least aportion of one or both of the second facets (i.e., the second and/orfourth facets 38B and 38D). In the examples shown in FIGS. 4-14, theportion 51 of the second outer side 50 that is substantially free of anycoating may comprise substantially an entirety of the second outer side50. In the examples shown in FIGS. 15-17, the portion 51 that issubstantially free of any coating may comprise only part of the secondouter side 50 (also referred to herein as a first portion or an uncoatedportion). A second portion 53 of the second outer side 50 may comprise asecond coating 62 disposed substantially thereon, such that only part ofthe second outer side 50 is uncoated.

With reference to FIGS. 15 and 16 and the labeling of the substrate 28in FIG. 4, the first portion 51 of the second outer side 50 that issubstantially free of any coating may extend from the tip region 35toward the base 32, and the second coating 62 may extend substantiallyfrom a first location 75-1 to a second location 75-2, in which the firstlocation 75-1 is spaced apart from the tip region 35 and the secondlocation 75-2 is located toward the base 32. In FIG. 15, the firstlocation 75-1 may substantially correspond to the junction 39-3 betweenthe blade body 30 and the fourth facet 38D, such that the uncoatedportion 51 of the second outer side 50 may comprise substantially anentirety of the second and fourth facets 38B and 38D. In FIG. 16, thefirst location 75-1 may substantially correspond to the junction 39-4between the second and fourth facets 38B and 38D, such that the uncoatedportion 51 of the second outer side 50 may comprise substantially anentirety of the fourth facet 38D. It may be understood that the secondcoating 62 may be disposed so that the uncoated portion 51 of the secondouter side 50 is located at any desired location within theseparameters.

With reference to FIG. 17 and the labeling of the substrate 28 in FIG.4, in further examples, the second coating 62 may comprise first andsecond sections 62-1 and 62-2, and the uncoated portion 51 of the secondouter side 50 may be located between the first and second sections 62-1and 62-2 of the second coating 62 such that the uncoated portion 51 isspaced apart from the tip region 35 and the base 32. For example, thefirst section 62-1 of the second coating 62 may extend substantiallyfrom a first location 75-1 to a second location 75-2, and the secondsection 62-2 may extend substantially from a third location 75-3 to afourth location 75-4. The first location 75-1 may substantiallycorrespond to the tip region 35 of the substrate 28, and the secondlocation 75-2 may be spaced apart from the third location 75-3. In theexample shown in FIG. 17, the second location 75-2 may substantiallycorrespond to the junction 39-4 between the second and fourth facets 38Band 38D; the third location 75-3 may substantially correspond to thejunction 39-3 between the blade body 30 and the fourth facet 38D; andthe fourth location 75-4 may be located toward the base 32 of thesubstrate 28, such that the uncoated portion 51 of the second outer side50 may comprise substantially an entirety of the second facet 38B. It isunderstood that the sections 62-1 and 62-2 of the second coating 62 maybe disposed so that the uncoated portion 51 of the second outer side 50is located at any desired location within these parameters.

In all examples, each coating may comprise one or more materials. Inexamples in which the substrate 28 comprises a coating with multiplelayers as shown in FIGS. 5-8, the layers may comprise the same materialsor one or more different materials, as compared to each other. Forexample, a first layer of a coating may comprise one or more firstmaterials, and a second layer of the coating may comprise one or moresecond materials, in which at least one of the second materials isdifferent from at least one of the first materials. In examples in whichthe substrate 28 comprises a coating with two or more sections as shownin FIGS. 9-11, each section may comprise a different material, ascompared to an adjacent or neighboring section. In examples in which thesubstrate 28 comprises first and second coatings as shown in FIGS.15-17, the coatings may comprise the same materials or one or moredifferent matierals, as compared to each other. For example, the firstcoating may comprise one or more first materials, and the second coatingmay comprise one or more second materials, in which at least one of thesecond materials is different from at least one of the first materials.

The materials may comprise one or more carbon-containing materials(e.g., diamond, amorphous diamond, nano-crystalline diamond, or diamondlike carbon (DLC)); nitrides (e.g., boron nitride, niobium nitride,chromium nitride, titanium nitride, aluminum titanium nitride, titaniumcarbon nitride), carbides (e.g., silicon carbide or chromium carbide),oxides (e.g., alumina, zirconia), titanium diboride, one or more ceramicmaterials, a fluorinated polymer (e.g., polytetrafluoroethylene (PTFE)),a polyolefin (e.g., polypropylene), niobium, chromium, and platinumchromium. The carbon-containing materials can be doped with otherelements, such as tungsten, titanium, or chromium by including theseadditives, for example, in the target during application by sputtering.The materials can also incorporate hydrogen, e.g., hydrogenated DLC. Thematerials may comprise one or more nanocomposites such as carbon-basednanocomposites, metal-matrix nanocomposites, and/or ceramic-matrixnanocomposites; e.g., diamond and carbon and nanocomposites.

The material(s) may be selected based, at least in part, on acoefficient of friction of the material(s), with the materials of thevarious coatings and/or layers and/or sections thereof comprising one ormore materials with a different coefficient of friction, as compared toeach other. For example, the coating 60 in FIG. 4 or an outer layer 60B,60C, 64B, 68B thereof in FIGS. 5-7 may comprise a material with a lowcoefficient of friction such as PTFE, particularly when the first outerside 48 of the substrate 28 at least partially defines theskin-contacting surface. When present, the second coating 62 (see FIGS.15-17) may comprise a material with a higher coefficient of frictionthan PTFE, such as polypropylene.

The material(s) of the coatings and/or layers and/or sections thereofmay also be selected based, at least in part, on morphology, which mayinclude microstructure (e.g., amorphous, columnar, crystalline, dense,porous, etc.) A porous microstructure may improve adhesion of asubsequent polymer coating. The desired morphology may be obtained, forexample, by applying the coatings and/or layers and/or sections thereofvia different application techniques or via the same applicationtechnique with differing application speeds, as described herein.

The material(s) of the coatings and/or layers and/or sections thereofmay further be selected based, at least in part, on a hardness of thematerial(s). One coating and/or layer and/or section thereof maycomprise a first hardness, and another coating and/or layer and/orsection thereof may comprise a second hardness. In some examples, thefirst hardness may be greater than about 7 GPa, and the second hardnessmay be greater than about twice the first hardness, e.g., greater thanabout 15 GPa. In other examples, the first hardness may be between about7 GPa to about 10 GPa, and the second hardness may be between about 15GPa to about 60 GPa. As used herein with respect to hardness, the term“about” may mean ±0.5 GPa.

A texture of the coatings and/or layers and/or sections thereof may alsobe selected. For example, the coating 60 in FIG. 4 or an outer layer60B, 60C, 64B, 68B thereof in FIGS. 5-7 may comprise a substantiallysmooth texture, particularly when the first outer side 48 of thesubstrate 28 at least partially defines the skin-contacting surface.When present, the second coating 62 (see FIGS. 15-17) may comprise adiscontinuous or more coarse texture that may include protrusions. Thedesired texture may be obtained by, for example, applying the coatingsand/or layers and/or sections thereof via different applicationtechniques or via the same application technique with differingapplication speeds, as described herein. The texture may also be alteredvia one or more post-application treatment methods, as described herein.

In further examples, at least a section of the coatings and/or layersand/or sections thereof may be subjected to one or more post-applicationtreatments (e.g., modification of a surface of the coating and/ormodification of one or more layers of the coating). For instance, one ormore sections of the coatings and/or layers and/or sections thereof maybe subjected to ion implantation. With reference to FIG. 13, at least asection of a coating 60′ may comprise an ion-implanted material 61. Theion-implanted material 61 may comprise, for example, a plasma-nitridedmaterial or a plasma-borided material. The ion implantation may beperformed as described herein and may be performed on all or part of thecoating 60′. The one or more post-application treatments may alsocomprise altering a texture of the coatings and/or layers and/orsections thereof. For example, the coatings and/or layers and/orsections thereof may be subjected to chemical modification (e.g.,solvent treatment) and/or mechanical modification (e.g., ion etching,ion implantation, abrading, rubbing, polishing, etc.) to alter a surfacetexture.

The one or more post-application treatments may further comprisepartially removing the coatings and/or layers and/or sections thereof,e.g., by solvent treatment, ion etching, etc. Partial removal maycomprise, for example, removal of all or part of a thickness of thecoating (i.e., in a direction substantially perpendicular to anunderlying portion of the substrate) along one or more sections of thesecond coating, in which at least a portion of the the coating remainsintact. In some examples, the partial removal of the one or moreportions of the coating may be followed by one or more additionalpost-application treatments comprising selectively applying material tothe coating from which material was partially removed. Theselectively-applied material may be applied using any suitable method.The selectively-applied material may comprise, for example, a polymer oran organic compound, such as a fluropolymer, PTFE, or polypropylene. Insome particular examples, the portion(s) of the coating to whichmaterial is selectively applied may define a skin-contacting surface ofthe razor blade.

With reference now to FIGS. 20-33, the razor blade 118 may comprise oneor more coatings that are substantially similar to the razor blade 18depicted in FIGS. 4-17 and described herein in detail, in which one ofthe first or the second outer side 148 or 150 of the substrate 128 maycomprise a coating and at least a portion 149 or 151 of the other of thefirst or the second outer side 148 or 150 of the substrate 128 may besubstantially free of any coating. In some particular examples in whichthe first outer side 148 comprises the coating, at least a portion ofthe first outer side 148 may define a skin-contacting surface. Theportion 149, 151 may extend from the tip region 135 toward the base 132,as shown in FIGS. 20-32, or may be spaced apart from the tip region 135and the base 132, as shown in FIG. 33.

As shown in FIGS. 20A, 21A, and 22A, the razor blade 118 may comprise acoating 160 disposed substantially on the first outer side 148 of thesubstrate 128 and extending along the first outer side 148 from the tipregion 135 toward the base (not shown; see base 132 in FIG. 18). Theportion 151 of the second outer side 150 that is substantially free ofany coating may extend from the tip region 135 toward the base. Thecoating 160 may comprise a single layer of material, as shown in FIG.20A, or a plurality of layers of material(s), e.g., first, second,and/or third layers 160A, 160B, and/or 160C, as shown in FIGS. 21A and22A. The first layer 160A is disposed substantially on the first outerside 148; the second layer 160B is formed on top of at least a portionof the first laye 160A; and when present, the third layer 160C is formedon top of at least a portion of the second layer 160B. FIGS. 20B, 21B,and 22B depict alternative configurations of respective ones of FIGS.20A, 21A, and 22A, in which the razor blade 118 comprises a coating 162disposed substantially on the second outer side 150 of the substrate 128and the first outer side 148 comprises the portion 149 that issubstantially free of any coating. The coating 162 extends along thefirst outer side 150 from the tip region 135 toward the base (not shown;see base 132 in FIG. 18). The portion 149 that is substantially free ofany coating may extend from the tip region 135 toward the base. Thecoating 162 may comprise a single layer of material, as shown in FIG.20B, or a plurality of layers of material(s), e.g., first, second,and/or third layers 162A, 162B, and/or 162C, as shown in FIGS. 21B and22B. As described herein, the coating(s) 160, 162 and/or any of thelayers 160A-160C, 162A-162C thereof may be subjected to ion implantationto generate, for example, a layer 160′ or 162′ comprising anion-implanted material 161 or 163, respectively, shown in FIGS. 29A and29B.

In the examples shown in FIGS. 20-22, the coatings 160 and 162(including all layers 160A-160C and 162A-162C thereof) are depicted asextending along the respective outer side 148 or 150 of the substrate128 from the tip region 135 onto the blade body (not labeled; see bladebody 130 in FIG. 18), and in some instances, may extend all the way tothe base (not shown; see base 132 in FIG. 18) of the razor blade 118. Inother examples, the coatings and/or one or more layers thereof may stopshort of the blade body and/or the base, and in some particularexamples, the coatings and/or one or more layers thereof may be disposedsubstantially only on the tip portion (not labeled; see 134 in FIG. 18)of the substrate 128, e.g., on one or both of the first and third facetsor one or both of the second and fourth facets (not labeled; see facets138A to 138D in FIG. 18).

With reference to FIGS. 23A and 24A and the labeling of the substrate128 in FIG. 18, a coating 164, 168 may comprise one or more layersincluding a first layer 164A, 168A that is disposed substantially on,and extends along a portion of, the first outer side 148 of thesubstrate 128 from the tip region 135 toward the base 132 for arespective first distance D₁₀, D_(10′); and a second layer 164B, 168Bthat is formed on top of at least a portion of the respective firstlayer 164A, 168B and extends from the tip region 135 toward the base 132for a respective second distance D₂₀, D_(20′). In some examples, thesecond distance D₂₀, D_(20′) may be less than the respective firstdistance D₁₀, D_(10′). In FIG. 23A, the first layer 164A may extendalong the first outer side 148 from the tip region 135 onto the bladebody 130 and toward the base 132, and the second layer 164B may bedisposed substantially on the first and third facets 138A and 138C, withthe second layer 164B extending from the tip region 135 to about thefirst junction 139-1 between the first facet 138A and the blade body130. In FIG. 24A, the first layer 168A may extend along the first outerside 148 from the tip region 135 onto the blade body 130 and toward thebase 132, and the second layer 168B may be disposed substantially on thethird facet 138C, with the second layer 168B extending from the tipregion 135 to about the second junction 139-2 between the first andsecond facets 138A and 138B. In other examples, the second distance D₂₀,D_(20′) may be about the same as the respective first distance D₁₀,D_(10′). In some instances (not shown), the first and second layers mayboth be disposed on the first and third facets 138A and 138C or only onthe third facet 138C.

FIGS. 23B and 24B depict alternative configurations of FIGS. 23A and24A, respectively, in which the second outer side 150 comprises acoating 166, 170 disposed substantially thereon, in which each coating166, 170 may comprise one or more layers including a respective firstlayer 166A, 170A and second layer 166B, 170B. Each first layer 166A,170A extends along a portion of the second outer side 150 from the tipregion 135 toward the base (not shown; see base 132 in FIG. 18) for arespective third distance D₃₀, D_(30′); and each second layer 166B, 170Bextends from the tip region 135 toward the base for a respective fourthdistance D₄₀, D_(40′). In some examples, the fourth distance D₄₀,D_(40′) may be less than the respective third distance D₃₀, D_(30′),e.g., the second layer 166B of the coating 166 in FIG. 23B is disposedsubstantially on the second and fourth facets (not labeled; see facets138B and 138D in FIG. 18) and the second layer 170B of the coating 170in FIG. 24B is disposed substantially on the fourth facet. In otherexamples, the fourth distance D₄₀, D_(40′) may be about the same as therespective third distance D₃₀, D_(30′). In the examples depicted inFIGS. 23 and 24, the coatings 164, 166, 168, and 170 may comprise twolayers, e.g., respective first layers 164A, 166A, 168A, and 170A andsecond layers 164B, 166B, 168B, and 170B. In other configurations, thecoatings 164, 166, 168, and 170 may comprise only the second layer 164B,166B, 168B, and 170B (the first layers 164A, 166A, 168A, and 170A areshown in dashed lines in FIGS. 23 and 24 indicating that they areoptional).

With reference to FIGS. 25A, 26A, and 27A, in further examples, acoating 172 may comprise two or more sections, including a first section172-1, a second section 172-2, and a third section 172-3. The firstsection 172-1 may extend along the first outer side 148 substantiallyfrom a first point or location 173-1, which may substantially correspondto a tip region 135 of the substrate 128, to a second point or location173-2; the second section 172-2 may extend substantially from the secondlocation 173-2 to a third point or location 173-3; and when present, thethird section 172-3 may extend substantially from the third location173-3 to a fourth point or location (not shown). With reference to FIG.25A and the labeling of the substrate 118 in FIG. 18, the secondlocation 173-2 may be positioned at about the junction 139-1 between thefirst facet 138A and the blade body 130, such that the first section172-1 may be located substantially on the first and third facets 138Aand 138C, and the second section 172-2 may be located substantially onthe blade body 130. With reference to FIG. 26A and the labeling of thesubstrate 118 in FIG. 18, the second location 173-2 may be positioned atabout the junction 139-2 between the first and third facets 138A and138C, such that the first section 172-1 may be located substantially onthe third facet 138C. In the examples depicted in FIGS. 25A and 26A, thethird location 173-3 may be spaced apart from the second location 173-2and may be located, for example, toward or near the base 132 of thesubstrate 128, as shown in FIG. 25A. With reference to FIG. 27A and thelabeling of the substrate 118 in FIG. 18, the second location 173-2 maybe positioned at about the junction 139-2 between the first and thirdfacets 138A and 138C, and the third location 173-3 may be positioned atabout the junction 139-1 between the first facet 138A and the blade body130, such that the first and second sections 172-1 and 172-2 may bedisposed substantially on the first and third facets 138A and 138C,respectively, and the third section 172-3 may be located substantiallyon the blade body 130. The fourth location (not shown) may be spacedapart from the third location 173-3 and may be located, for example,toward or near the base 132 of the substrate 128.

FIGS. 25B, 26B, and 27B depict alternative configurations of FIGS. 25A,26A, and 27A, respectively, in which the second outer side 150 comprisesa coating 174 comprising two or more sections, including a first section174-1, a second section 174-2, and a third section 174-3. The firstsection 174-1 may extend along the second outer side 150 substantiallyfrom a first point or location 175-1 (may substantially correspond to atip region 135 of the substrate 128) to a second point or location175-2; the second section 174-2 may extend substantially from the secondlocation 175-2 to a third point or location 175-3, and when present, thethird section 174-3 may extend substantially from the third location175-3 to a fourth point or location (not shown).

With reference to FIGS. 28A and 28B, in further examples, one of thefirst or the second outer side 148 or 150 of the substrate 128 maycomprise a respective coating 176 or 178 with a thickness that variesalong at least a section of the coating 176 and 178 in a directionextending from the tip region 135 toward the base 132. The thickness ofthe coating 176 and 178 may be measured between an outer surface 176A,178A of the respective coating 176 and 178 and an outer surface 128A ofthe substrate 128. The coatings 176 and 178 may, for example, increasein thickness, as shown in FIGS. 28A and 28B.

In the examples shown in FIGS. 20-28, an outer shape of the coatings160, 162, 164, 166, 168, 170, 172, 174, 176, and 178 (and all layers orsections thereof) generally conform to and/or mirror an outer shape ofthe underlying portions of the substrate 128 on which the coatings areformed. In other examples, as shown in FIGS. 30A and 30B, the substrate128 may comprise a coating 180 or 182 with one or more sections thatdefine an outer shape that is different from an outer shape of anunderlying portion of the substrate 128. As shown in FIG. 30A, thecoating 180 may be disposed substantially on the first outer side 148and may comprise a thickened section 180A where the coating 180 bulgesoutward from the substrate 128 and forms an outer shape that isdifferent from an outer shape of one or more of the underlying portionsof the substrate 128, e.g., the third facet outer surface and at least aportion of the first facet outer surface (not labeled; see facet outersurfaces 139A and 139C in FIG. 18). As shown in FIG. 30B, the coating182 may be disposed substantially on the second outer side 150 and maycomprise a thickened section 182A where the coating 182 bulges outwardfrom the substrate 128 and forms an outer shape that is different froman outer shape of one or more of the underlying portions of thesubstrate 128, e.g., the fourth facet outer surface and at least aportion of the second facet outer surface (not labeled; see facet outersurfaces 139B and 139D in FIG. 18). The coatings 180 and 182 mayoptionally comprise a respective second section 180B and 182B with anouter shape that conforms more closely to the outer shape of theunderlying portion(s), e.g., the first or second blade body outersurface (not shown; see blade body outer surface 131A, 131B in FIG. 18),of the substrate 128.

In FIGS. 20A, 21A, 22A, 23A, 24A, 25A, 26A, 27A, 28A, 29A, and 30A, thecoatings 160, 164, 168, 172, 176, and 180 may be disposed on one or bothof the first facets (i.e., the first and/or third facets 138A and 138Cin FIG. 18) on the first outer side 148 of the substrate 128, and theportion 151 of the second outer side 150 that is free of any coating maycomprise at least a portion of one or both of the second facets (i.e.,the second and/or fourth facets 138B and 138D in FIG. 18). In FIGS. 20B,21B, 22B, 23B, 24B, 25B, 26B, 27B, 28B, 29B, and 30B, the coatings 162,166, 170, 174, 178, and 182 may be disposed on one or both of the secondfacets (i.e., the second and/or fourth facets 138B and 138D in FIG. 18)on the second outer side 150 of the substrate 128, and the portion 149of the first outer side 148 that is free of any coating may comprise atleast a portion of one or both of the first facets (i.e., the firstand/or third facets 138A and 138C in FIG. 18). In the examples shown inFIGS. 20-30, the portion 149 or 151 of the outer side 148 or 150 that issubstantially free of any coating may comprise substantially an entiretyof the respective outer side 148 or 150. In the examples shown in FIGS.31-33, the portion 151 that is substantially free of any coating maycomprise only part of the second outer side 150 (also referred to hereinas a first portion or an uncoated portion). A second portion 153 of thesecond outer side 150 may comprise a second coating 162 disposedsubstantially thereon, such that only part of the second outer side 150is uncoated.

With reference to FIGS. 31 and 32 and the labeling of the substrate 128in FIG. 18, the first portion 151 of the second outer side 150 that issubstantially free of any coating may extend from the tip region 135toward the base 132, and the second coating 162 may extend substantiallyfrom a first location 175-1 to a second location 175-2, in which thefirst location 175-1 is spaced apart from the tip region 135 and thesecond location 175-2 is located toward the base 132. In FIG. 31, thefirst location 175-1 may substantially correspond to the junction 139-3between the blade body 130 and the fourth facet 138D, such that theuncoated portion 151 of the outer side 150 may comprise substantially anentirety of the second and fourth facets 138B and 138D. In FIG. 32, thefirst location 175-1 may substantially correspond to the junction 139-4between the second and fourth facets 138B and 138D, such that theuncoated portion 151 of the outer side 150 may comprise substantially anentirety of the fourth facet 138D. It may be understood that the secondcoating 162 may be disposed so that the uncoated portion 151 of theouter side 150 is located at any desired location within theseparameters.

With reference to FIG. 33 and the labeling of the substrate 128 in FIG.18, in further examples, the second coating 162 may comprise first andsecond sections 162-1 and 162-2, and the uncoated portion 151 of thesecond outer side 150 may be located between the first and secondsections 162-1 and 162-2 of the second coating 162, such that theuncoated portion 151 is spaced apart from the tip region 135 and thebase 132. For example, the first section 162-1 of the second coating 162may extend substantially from a first location 175-1 to a secondlocation 175-2, and the second section 162-2 may extend substantiallyfrom a third location 175-3 to a fourth location 175-4. The firstlocation 175-1 may substantially correspond to the tip region 135 of thesubstrate 128, and the second location 175-2 may be spaced apart fromthe third location 175-3. In the example shown in FIG. 33, the secondlocation 175-2 may substantially correspond to the junction 139-4between the second and fourth facets 138B and 138D; the third location175-3 may substantially correspond to the junction 139-3 between theblade body 130 and the fourth facet 138D; and the fourth location 175-4may be located toward the base 132 of the substrate 128, such that theuncoated portion 151 of the outer side 150 may comprise substantially anentirety of the second facet 138B. It is understood that the sections162-1 and 162-2 of the second coating 162 may be disposed so that theuncoated portion 151 of the second outer side 150 is located at anydesired location within these parameters. In addition, although theuncoated portion 151 is depicted in FIGS. 31-33 as being located on thesecond outer side 150, it is understood that the uncoated portion 151could also be located on the first outer side 148 (not shown).

The coatings depicted in FIGS. 20-33 and/or layers and/or sectionsthereof may comprise one or more materials, as described herein indetail with respect to FIGS. 4-17. The material(s) may be selected forany of the properties and characteristics described herein (e.g.,coefficient of friction, morphology, texture, hardness, etc.), and atleast a section of the coatings and/or layers and/or sections thereofmay be subjected to one or more post-application treatments, asdescribed herein in detail. For example, one or more sections of thecoatings and/or layers and/or sections thereof may be subjected to ionimplantation, as shown in FIGS. 29A and 29B in which at least a sectionof a coating 160′, 162′ may comprise an ion-implanted material 161, 163.

FIGS. 34-37 are detailed views of a tip region 35 of a substrate 28,which may represent any of the substrates 28 and 128 in FIGS. 4-17 and20-33. FIG. 34 depicts an idealized representation of a the tip region35 in which a coating 60 is disposed only on the first outer side 48 ofthe substrate 28, i.e., on the left side of a split line S₂₈ of thesubstrate 28, and at least a portion 51 of the second outer side 50 ofthe substrate 28, i.e., on the right side of a split line S₂₈, is freeof any coating.

However, application of material(s) to a substrate 228 may produce a tipregion 235 with slight imperfections, as illustrated in FIGS. 35-37. InFIGS. 35-37, a first outer side 248 of a substrate 228 (as defined by asplit line SL₂₂₈) may comprise a coating 260 with a first layer 260A anda second layer 260B, and a portion 251 of a second outer side 250 may besubstantially free of any coating. As shown in FIGS. 35 and 36, in someexamples, a small portion of the coating 260 (may include one or both ofthe layers 260A and 260B) may be disposed on the second outer side 250of the substrate 228 at the tip region 235, i.e., a small portion(extending less than or equal to about 1 μM back from the tip 240 towardthe base) of the coating 260 may be located to the right of the splitline SL₂₂₈. FIG. 37 provides a further example in which the coating 260stops slightly short of the tip 240, such that there is a small gap(less than or equal to about 1 μM) between the coating 260 and the tip240.

In the examples described herein, notwithstanding a small amount(extending less than or equal to about 1 μM back from the tip 240 towardthe base) of overlap by the coating 260 onto the second outer side 250or a gap (less than or equal to about 1 μM) between the coating 260 andthe tip 240 in the tip region 235, the coating 260, including all layers260A and 260B thereof, is considered to be disposed “substantially” onthe first outer side 248 of the substrate 228 and to extend “from thetip region” when the majority of the coating 260 is disposed on thefirst outer side 248 of the substrate 228. In addition, the portion ofthe second side 250 extending “from the tip region toward the base” inFIGS. 35 and 36 is considered to be “substantially free of any coating,”notwithstanding the small amount of overlap by the coating 260 onto thesecond outer side 250. Although the examples shown in FIGS. 34-37 depictthe coating as being located on the first outer side 248 of thesubstrate 228, it is understood that the coating could also be locatedon the second outer side 250.

In examples in which the first and/or second coating comprise two ormore layers (see FIGS. 5-8 and 21-24) and/or two or more sections (seeFIGS. 9-11 and 25-27), each layer or section is described as extendingfrom one point or location to another point or location on the substrate(e.g., a junction between adjacent ones of the facets or a junctionbetween the blade body and one of the facets) and, in some examples, asection may adjoin and contact at least a portion of an adjacentsection.

Similar to the structures depicted in FIGS. 35-37, the layers and/orsections may extend slightly beyond (less than or equal to about 1 μM),or stop slightly short of (less than or equal to about 1 μM), one orboth of the identified locations. In some cases, there may be a smallamount of mixing of materials at an interface between two adjacentsections or a small gap between the adjacent sections (less than orequal to about 1 μM). Notwithstanding these slight imperfections, alayer or section of a coating may be considered to extend“substantially” from one location to another location when the majorityof the layer/section is disposed between the two identified locations.

The coatings described herein may be applied or selectively removedusing one more techniques. FIG. 38 is a block diagram of a system 300having one or more chambers and/or stations 302-1 to 302-n that may beused to apply one or more coatings to one or more portions of aplurality of razor blades 318 and/or to perform one or morepost-application treatments following application of the one or morecoatings. As shown, the razor blades 318 may be positioned within afirst chamber 302-1 for application of one or more coatings using one ormore techniques, such as vacuum deposition, spraying, dipping, brushing,molding, sintering, printing, etching, application via a pad or paint,ink-jet nozzle, or any combination thereof, any of which may or may notinclude masking one or more portions of the razor blades 318. In someexamples, the chamber 302-1 may comprise a vacuum chamber with a vacuumpump 390. The system 300 may optionally comprise one or more additionalchambers 302-n for performing different coating techniques and/or toperform different post-application treatments.

The razor blades 318 may represent any razor blade described herein. Therazor blades 318 may be arranged in any manner within the chamber 302-1.As shown, the razor blades 318 may be positioned adjacent to each otherin an arrangement that may be referred to as a razor blade spindle. Theblades 318 may also be disposed with a space in between each other (notshown) using spacers, which may allow coating coverage onto the bladebodies 330 of the razor blades 318 to be increased. The blades 318 mayalso be disposed with the edges (not labeled) and tips 340 facing inopposite directions or at different angles from each other (not shown).Any feasible orientation of the razor blades 318 is contemplated in thepresent disclosure.

The system 300 may be used to apply coatings to a razor blade, in whichthe razor blade comprises a substrate with first and second outer sidesdisposed opposite a split line. First and second coatings are applied toat least a portion of the first and second outer sides, with the firstand second coatings extending from a tip region of the substrate towarda base and being disposed substantially on the respective first orsecond outer side. The coatings may each comprise one or more layers.

The system 300 may be configured to accommodate the application ofmultiple different kinds of materials, as described herein, includingmetals, fluorinated polymers, etc. The first and second coatings may beapplied simultaneously or sequentially and may be applied using the sameor different technique. In some examples, selective application of oneor more materials may be accomplished by, for example, masking one ormore portions of the substrate and applying the material(s) to theunmasked portion(s) of the substrate. The system 300 may also beconfigured to apply the first and second coatings to generate one ormore desired properties for each coating, including a particularthickness, outer shape, morphology, texture, etc., as described herein.The system 300 may further be configured to perform one or morepost-application treatments on at least one section of the first coatingor the second coating, including ion implantation and/or altering atexture of the coating(s).

FIG. 39 is a flow diagram illustrating an exemplary method 400 ofcoating a razor blade in accordance with the present disclosure. Withreference to FIGS. 4 and 18, the razor blades 18, 118 may comprise asubstrate 28, 128 having a tip portion 34, 134 comprising a tip region35, 135, a blade body 30, 130 comprising a base 32, 132, and first andsecond outer sides 48, 148 and 50, 150 disposed opposite a split lineSL₂₈, SL₁₂₈ of the substrate 28, 128, in which the first and secondouter sides 48, 148 and 50, 150 converge at a tip 40, 140. The method400 comprises either Step 410, which includes applying a first coatingonly to a portion of the first outer side, in which the coating extendsfrom the tip region toward the base and is disposed substantially on thefirst outer side, or Step 420, which includes applying a first coatingto a portion of the first outer side, in which the first coating extendsfrom the tip region toward the base and is disposed substantially on thefirst outer side, and applying a second coating to the second outer sidesuch that a first portion of the second outer side is substantially freeof any coating and a second portion of the second outer side comprisesthe second coating, in which the first portion extends from the tipregion toward the base or is spaced apart from the tip region and thebase, after which the method 400 may conclude.

In some particular examples, the substrate may comprise the secondcoating. In some instances, the second coating may extend substantiallyfrom a first location to a second location, the first location beingspaced apart from the tip region and the second location being locatedtoward the base. In other instances, the second coating may comprise afirst section extending substantially from a first location to a secondlocation and a second section extending substantially from a thirdlocation to a fourth location, in which the first location may comprisethe tip region, the second location may be spaced apart from the thirdlocation, and the first portion of the second outer side that issubstantially free of any coating may be located between the first andsecond sections of the second coating. The first coating may compriseone or more first materials and the second coating may comprise one ormore second materials, in which at least one of the second materials maybe different from at least one of the first materials. The first andsecond coatings may be applied simultaneously or sequentially and/orusing a same technique or different technique.

The first coating may be applied such that at least a section of thefirst coating defines an outer shape that is different from an outershape of an underlying portion of the substrate or such that the firstcoating comprises a thickness that varies along at least a section ofthe first coating in a direction extending from the tip region towardthe base of the razor blade.

In some examples, the Step 410 of applying the first coating may furthercomprise applying a plurality of layers of material. Applying theplurality of layers of material may comprise: applying a first layer tothe portion of the first outer side, in which the first layer extendsfrom the tip region toward the base for a first distance; and applying asecond layer on top of at least a section of the first layer, in whichthe second layer extends from the tip region toward the base for asecond distance that is the same as or less than the first distance. Thefirst layer may comprise a first material and the second layer maycomprise a second material that is different from the first material.

In other examples, the first outer side of the substrate may compriseone or more first facets and the second outer side may comprise one ormore second facets. The first coating may be disposed on at least one ofthe first facets and the first portion of the second outer side that issubstantially free of any coating may comprise at least a portion of oneof at least one of the second facets. The first coating may be appliedsuch that the first coating comprises: a first section extendingsubstantially from a first location to a second location on the firstouter side; and a second section extending substantially from the secondlocation to a third location on the first outer side, in which the firstlocation may comprise the tip region and the second location maycomprise a junction between (i) two adjacent ones of the first facets,or (ii) the blade body and one of the first facets. The second locationmay comprise the junction between two adjacent ones of the first facetsand the third location may comprise the junction between the blade bodyand one of the first facets, in which the first coating may be appliedsuch that the first coating further comprises a third section extendingsubstantially from the third location toward the base.

In further examples, the method may further comprise option Step 430,which includes performing one or more post-application treatments on atleast one section of the first coating and/or when the substratecomprises the second coating, performing one or more post-applicationtreatments on at least one section of the second coating. In someinstances, the one or more post-application treatments may comprise oneor more of: subjecting the at least one section of the first and/orsecond coating to ion implantation; or partially removing one or moresections of the first and/or second coating. In other instances, the oneor more post-application treatments may further comprise selectivelyapplying material to the first and/or second coating following partialremoval of the one or more sections of the first and/or second coating.At least a portion of the first or the second outer side with theselective applied material may define a skin-contacting surface.

Representative embodiments of the present disclosure described above canbe described as follows:

A. A razor blade comprising:

-   -   a substrate having a tip portion comprising a tip region, a        blade body comprising a base, and first and second outer sides        disposed opposite a split line of the substrate, wherein the        first and second outer sides converge at a tip,    -   wherein the first outer side comprises a first coating disposed        substantially thereon, the first coating extending from the tip        region toward the base, and    -   wherein a first portion of the second outer side is        substantially free of any coating, wherein the first portion        extends from the tip region toward the base or is spaced apart        from the tip region and the base.

B. The razor blade of paragraph A, wherein a second portion of thesecond outer side comprises a second coating disposed substantiallythereon, the second coating extending substantially from a firstlocation to a second location, wherein the first location is spacedapart from the tip region and the second location is located toward thebase.

C. The razor blade of paragraph A or B, wherein the first portioncomprises substantially an entirety of the second outer side.

D. The razor blade of any paragraphs A or C, wherein a second portion ofthe second outer side comprises a second coating disposed substantiallythereon, the second coating comprising a first section extendingsubstantially from a first location to a second location and a secondsection extending substantially from a third location to a fourthlocation, wherein the first location comprises the tip region, thesecond location is spaced apart from the third location, and the firstportion of the second outer side that is substantially free of anycoating is located between the first and second sections of the secondcoating.

E. The razor blade of any of paragraphs A to D, wherein at least aportion of the first outer side defines a skin-contacting surface.

F. The razor blade of any of paragraphs A to E, wherein the split linesplits the substrate into two substantially equal halves.

G. The razor blade of any of paragraphs A to F, wherein the split linesplits the substrate into two asymmetrical halves.

H. The razor blade of any of paragraphs A to G, wherein the firstcoating comprises a plurality of layers of material.

I. The razor blade of paragraph H, wherein the first coating comprises:

-   -   a first layer disposed substantially on the first outer side and        extending from the tip region toward the base for a first        distance; and    -   a second layer disposed on top of at least a section of the        first layer and extending from the tip region toward the base        for a second distance that is the same as or less than the first        distance.

J. The razor blade of paragraph I, wherein the first layer comprises afirst material and the second layer comprises a second material that isdifferent from the first material.

K. The razor blade of any of paragraphs A to J, wherein the firstcoating comprises a thickness that varies along at least a section ofthe first coating in a direction extending from the tip region towardthe base of the razor blade.

L. The razor blade of any of paragraphs A to K, wherein the firstcoating comprises an ion-implanted material.

M. The razor blade of any of paragraphs A to L, wherein at least asection of the first coating defines an outer shape that is differentfrom an outer shape of an underlying portion of the substrate.

N. The razor blade of of any of paragraphs A, C, or E to M, a secondportion of the second outer side comprises a second coating disposedsubstantially thereon.

O. The razor blade of paragraph N, wherein the first coating comprisesone or more first materials and the second coating comprises one or moresecond materials, at least one of the second materials being differentfrom at least one of the first materials.

P. The razor blade of any of paragraphs A to 0, wherein the first outerside comprises one or more first facets and the second outer sidecomprises one or more second facets.

Q. The razor blade of paragraph P, wherein the first coating is disposedon at least one of the first facets and the first portion of the secondouter side that is substantially free of any coating comprises at leasta portion of one of at least one of the second facets.

R. The razor blade of paragraph P, wherein the first coating comprises:

-   -   a first section extending substantially from a first location to        a second location on the first outer side; and    -   a second section extending substantially from the second        location to a third location on the first outer side, wherein        the first location comprises the tip region and the second        location comprises a junction between (i) two adjacent ones of        the first facets, or (ii) the blade body and one of the first        facets.

S. The razor blade of paragraph R, wherein the second location comprisesthe junction between two adjacent ones of the first facets and the thirdlocation comprises the junction between the blade body and one of thefirst facets, the first coating further comprising a third sectionextending substantially from the third location toward the base.

T. A method of coating a razor blade comprising a substrate having a tipportion comprising a tip region, a blade body comprising a base, andfirst and second outer sides disposed opposite a split line of thesubstrate, wherein the first and second outer sides converge at a tip,the method comprising one of:

-   -   (i) applying a first coating only to a portion of the first        outer side, the coating extending from the tip region toward the        base and being disposed substantially on the first outer side;        or    -   (ii) applying a first coating to a portion of the first outer        side, the first coating extending from the tip region toward the        base and being disposed substantially on the first outer side,        and applying a second coating to the second outer side such that        a first portion of the second outer side is substantially free        of any coating and a second portion of the second outer side        comprises the second coating, wherein the first portion extends        from the tip region toward the base or is spaced apart from the        tip region and the base.

U. The method of paragraph T, wherein the substrate comprises the secondcoating.

V. The method of paragraph U, wherein the second coating extendssubstantially from a first location to a second location, the firstlocation being spaced apart from the tip region and the second locationbeing located toward the base.

W. The method of paragraph U, wherein the second coating comprises afirst section extending substantially from a first location to a secondlocation and a second section extending substantially from a thirdlocation to a fourth location, the first location comprising the tipregion and the second location being spaced apart from the thirdlocation, wherein the first portion of the second outer side that issubstantially free of any coating is located between the first andsecond sections of the second coating.

X. The method of any of paragraphs U to W, wherein the first coatingcomprises one or more first materials and the second coating comprisesone or more second materials, at least one of the second materials beingdifferent from at least one of the first materials.

Y. The method of any of paragraphs U to X, wherein the first and secondcoatings are applied simultaneously.

Z. The method of any of paragraphs U to X, wherein the first and secondcoatings are applied sequentially.

AA. The method of any of paragraphs U to Z, wherein the first and secondcoatings are applied using a same technique.

BB. The method of any of parargraphs U to Z, wherein the first coatingis applied with a first technique and the second coating is applied witha second technique that is different from the first technique.

CC. The method of any of paragraphs T to BB, wherein the first coatingis applied such that at least a section of the first coating defines anouter shape that is different from an outer shape of an underlyingportion of the substrate.

DD. The method of any of paragraphs T to CC, wherein the first coatingis applied such that the first coating comprises a thickness that variesalong at least a section of the first coating in a direction extendingfrom the tip region toward the base of the razor blade.

EE. The method of any of paragraphs T to DD, wherein applying the firstcoating further comprises applying a plurality of layers of material.

FF. The method of paragraph EE, wherein applying the plurality of layersof material comprises:

-   -   applying a first layer to the portion of the first outer side,        the first layer extending from the tip region toward the base        for a first distance; and    -   applying a second layer on top of at least a section of the        first layer, the second layer extending from the tip region        toward the base for a second distance that is the same as or        less than the first distance.

GG. The method of paragraph FF, wherein the first layer comprises afirst material and the second layer comprises a second material that isdifferent from the first material.

HH. The method of any of paragraphs T to GG, wherein the first outerside of the substrate comprises one or more first facets and the secondouter side comprises one or more second facets.

II. The method of paragraph HH, wherein the first coating is disposed onat least one of the first facets and the first portion of the secondouter side that is substantially free of any coating comprises at leasta portion of one of at least one of the second facets.

JJ. The method of paragraph HH, wherein the first coating is appliedsuch that the first coating comprises:

-   -   a first section extending substantially from a first location to        a second location on the first outer side; and    -   a second section extending substantially from the second        location to a third location on the first outer side, wherein        the first location comprises the tip region and the second        location comprises a junction between (i) two adjacent ones of        the first facets, or (ii) the blade body and one of the first        facets.

KK. The method of paragraph JJ, wherein the second location comprisesthe junction between two adjacent ones of the first facets and the thirdlocation comprises the junction between the blade body and one of thefirst facets, the first coating being applied such that the firstcoating further comprises:

-   -   a third section extending substantially from the third location        toward the base.

LL. The method of any of paragraphs T to JJ, further comprising:

-   -   performing one or more post-application treatments on at least        one section of the first coating.

MM. The method of paragraph MM, wherein the one or more post-applicationtreatments comprise one or more of:

-   -   subjecting at least one section of the first coating to ion        implantation; or    -   partially removing one or more sections of the first coating.

NN. The method of paragraph MM, wherein the one or more post-applicationtreatments further comprise selectively applying material to the firstcoating following partial removal of the one or more sections of thefirst coating.

OO. The method of paragraph NN, wherein at least a portion of the firstouter side with the material defines a skin-contacting surface.

PP. The method of any of paragraphs TT to JJ, wherein the substratecomprises the second coating, the method further comprising:

-   -   performing one or more post-application treatments on at least        one section of the second coating.

QQ. The method of paragraph PP, wherein the one or more post-applicationtreatments comprise partially removing one or more sections of thesecond coating.

The illustrations presented herein are not intended to be actual viewsof any particular substrate, apparatus (e.g., device, system, etc.), ormethod, but are merely idealized and/or schematic representations thatare employed to describe and illustrate various embodiments of thedisclosure.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A razor blade comprising: a substrate having atip portion comprising a tip region, a blade body comprising a base, andfirst and second outer sides disposed opposite a split line of saidsubstrate, wherein said first and second outer sides converge at a tip,wherein said first outer side comprises a first coating disposedsubstantially thereon, said first coating extending from said tip regiontoward said base, and wherein a first portion of said second outer sideis substantially free of any coating, wherein said first portion extendsfrom said tip region toward said base or is spaced apart from said tipregion and said base.
 2. The razor blade of claim 1, wherein a secondportion of said second outer side comprises a second coating disposedsubstantially thereon, said second coating extending substantially froma first location to a second location, wherein said first location isspaced apart from said tip region and said second location is locatedtoward said base.
 3. The razor blade of claim 1, wherein said firstportion comprises substantially an entirety of said second outer side.4. The razor blade of claim 1, wherein a second portion of said secondouter side comprises a second coating disposed substantially thereon,said second coating comprising a first section extending substantiallyfrom a first location to a second location and a second sectionextending substantially from a third location to a fourth location,wherein said first location comprises said tip region, said secondlocation is spaced apart from said third location, and said firstportion of said second outer side that is substantially free of anycoating is located between said first and second sections of said secondcoating.
 5. The razor blade of claim 1, wherein at least a portion ofsaid first outer side defines a skin-contacting surface.
 6. The razorblade of claim 1, wherein said split line splits said substrate into twosubstantially equal halves.
 7. The razor blade of claim 1, wherein saidsplit line splits said substrate into two asymmetrical halves.
 8. Therazor blade of claim 1, wherein said first coating comprises a pluralityof layers of material.
 9. The razor blade of claim 8, wherein said firstcoating comprises: a first layer disposed substantially on said firstouter side and extending from said tip region toward said base for afirst distance; and a second layer disposed on top of at least a sectionof said first layer and extending from said tip region toward said basefor a second distance that is the same as or less than said firstdistance.
 10. The razor blade of claim 9, wherein said first layercomprises a first material and said second layer comprises a secondmaterial that is different from said first material.
 11. The razor bladeof claim 1, wherein said first coating comprises a thickness that variesalong at least a section of said first coating in a direction extendingfrom said tip region toward said base of said razor blade.
 12. The razorblade of claim 1, wherein said first coating comprises an ion-implantedmaterial.
 13. The razor blade of claim 1, wherein at least a section ofsaid first coating defines an outer shape that is different from anouter shape of an underlying portion of said substrate.
 14. The razorblade of claim 1, a second portion of said second outer side comprises asecond coating disposed substantially thereon.
 15. The razor blade ofclaim 14, wherein said first coating comprises one or more firstmaterials and said second coating comprises one or more secondmaterials, at least one of said second materials being different from atleast one of said first materials.
 16. The razor blade of claim 1,wherein said first outer side comprises one or more first facets andsaid second outer side comprises one or more second facets.
 17. Therazor blade of claim 16, wherein said first coating is disposed on atleast one of said first facets and said first portion of said secondouter side that is substantially free of any coating comprises at leasta portion of one of at least one of said second facets.
 18. The razorblade of claim 16, wherein said first coating comprises: a first sectionextending substantially from a first location to a second location onsaid first outer side; and a second section extending substantially fromsaid second location to a third location on said first outer side,wherein said first location comprises said tip region and said secondlocation comprises a junction between (i) two adjacent ones of saidfirst facets, or (ii) said blade body and one of said first facets. 19.The razor blade of claim 18, wherein said second location comprises saidjunction between two adjacent ones of said first facets and said thirdlocation comprises said junction between said blade body and one of saidfirst facets, said first coating further comprising a third sectionextending substantially from said third location toward said base.
 20. Amethod of coating a razor blade comprising a substrate having a tipportion comprising a tip region, a blade body comprising a base, andfirst and second outer sides disposed opposite a split line of saidsubstrate, wherein said first and second outer sides converge at a tip,the method comprising one of: (i) applying a first coating only to aportion of said first outer side, said coating extending from said tipregion toward said base and being disposed substantially on said firstouter side; or (ii) applying a first coating to a portion of said firstouter side, said first coating extending from said tip region towardsaid base and being disposed substantially on said first outer side, andapplying a second coating to said second outer side such that a firstportion of said second outer side is substantially free of any coatingand a second portion of said second outer side comprises said secondcoating, wherein said first portion extends from said tip region towardsaid base or is spaced apart from said tip region and said base.
 21. Themethod of claim 20, wherein said substrate comprises said secondcoating.
 22. The method of claim 21, wherein said second coating extendssubstantially from a first location to a second location, said firstlocation being spaced apart from said tip region and said secondlocation being located toward said base.
 23. The method of claim 21,wherein said second coating comprises a first section extendingsubstantially from a first location to a second location and a secondsection extending substantially from a third location to a fourthlocation, said first location comprising said tip region and said secondlocation being spaced apart from said third location, wherein said firstportion of said second outer side that is substantially free of anycoating is located between said first and second sections of said secondcoating.
 24. The method of claim 21, wherein said first coatingcomprises one or more first materials and said second coating comprisesone or more second materials, at least one of said second materialsbeing different from at least one of said first materials.
 25. Themethod of claim 21, wherein said first and second coatings are appliedsimultaneously.
 26. The method of claim 21, wherein said first andsecond coatings are applied sequentially.
 27. The method of claim 21,wherein said first and second coatings are applied using a sametechnique.
 28. The method of claim 21, wherein said first coating isapplied with a first technique and said second coating is applied with asecond technique that is different from said first technique.
 29. Themethod of claim 20, wherein said first coating is applied such that atleast a section of said first coating defines an outer shape that isdifferent from an outer shape of an underlying portion of saidsubstrate.
 30. The method of claim 20, wherein said first coating isapplied such that said first coating comprises a thickness that variesalong at least a section of said first coating in a direction extendingfrom said tip region toward said base of said razor blade.
 31. Themethod of claim 20, wherein applying said first coating furthercomprises applying a plurality of layers of material.
 32. The method ofclaim 31, wherein applying said plurality of layers of materialcomprises: applying a first layer to said portion of said first outerside, said first layer extending from said tip region toward said basefor a first distance; and applying a second layer on top of at least asection of said first layer, said second layer extending from said tipregion toward said base for a second distance that is the same as orless than said first distance.
 33. The method of claim 32, wherein saidfirst layer comprises a first material and said second layer comprises asecond material that is different from said first material.
 34. Themethod of claim 20, wherein said first outer side of said substratecomprises one or more first facets and said second outer side comprisesone or more second facets.
 35. The method of claim 34, wherein saidfirst coating is disposed on at least one of said first facets and saidfirst portion of said second outer side that is substantially free ofany coating comprises at least a portion of one of at least one of saidsecond facets.
 36. The method of claim 34, wherein said first coating isapplied such that said first coating comprises: a first sectionextending substantially from a first location to a second location onsaid first outer side; and a second section extending substantially fromsaid second location to a third location on said first outer side,wherein said first location comprises said tip region and said secondlocation comprises a junction between (i) two adjacent ones of saidfirst facets, or (ii) said blade body and one of said first facets. 37.The method of claim 36, wherein said second location comprises saidjunction between two adjacent ones of said first facets and the thirdlocation comprises said junction between said blade body and one of saidfirst facets, said first coating being applied such that said firstcoating further comprises: a third section extending substantially fromsaid third location toward said base.
 38. The method of claim 20,further comprising: performing one or more post-application treatmentson at least one section of said first coating.
 39. The method of claim38, wherein said one or more post-application treatments comprise one ormore of: subjecting at least one section of said first coating to ionimplantation; or partially removing one or more sections of said firstcoating.
 40. The method of claim 38, wherein said one or morepost-application treatments further comprise selectively applyingmaterial to said first coating following partial removal of said one ormore sections of said first coating.
 41. The method of claim 40, whereinat least a portion of said first outer side with said material defines askin-contacting surface.
 42. The method of claim 20, wherein saidsubstrate comprises said second coating, the method further comprising:performing one or more post-application treatments on at least onesection of said second coating.
 43. The method of claim 42, wherein saidone or more post-application treatments comprise partially removing oneor more sections of said second coating.